Chlorine generator system

ABSTRACT

A chlorine generator apparatus wherein a housing is adapted to be mounted in an exterior, user-accessible surface of a spa and a chlorine generating electrode cartridge carrying a pair of electrodes is configured to be installable by a user in the housing and to thereafter be removable by the user for replacement.

RELATED APPLICATIONS

This application is a divisional of, and claims the benefit of andpriority to, U.S. patent application Ser. No. 15/651,709, filed July.17, 2017, and entitled “Chlorine Generator System,” which application isincorporated by reference herein in its entirety.

FIELD

The subject disclosure relates to chlorine generating systems and moreparticularly to a chlorine generator system for spas, tubs, pools andthe like which features a disposable and consumer replaceable electrodecartridge.

DESCRIPTION OF RELATED ART

Various chlorine generating devices have been constructed in the past,for example, such as the drop-in chlorinator disclosed in U.S. Pat. No.8,745,774, assigned to Watkins Manufacturing Corporation of Vista,Calif.

SUMMARY

Illustrative embodiments provide a chlorine generator installed in a spaand having a disposable and consumer replaceable electrode cartridge.

According to one embodiment, a chlorine generator apparatus comprises ahousing adapted to be mounted in a user-accessible exterior surface of aspa and a chlorine generating electrode cartridge mounted in the housingand carrying first and second electrodes wherein the electrode cartridgeis configured to be replaceable by a user.

According to another aspect of the disclosure, a housing is provided forreceiving an electrode cartridge comprising a wall fitting mounted to aconsumer-accessible surface of a spa and a cap removably attachable tothe wall fitting by a user to provide user access to the electrodecartridge. In one embodiment, the housing may further comprise a lowerhousing section attached to a lower end of the wall fitting. The lowerhousing section may provide an electrode chamber wherein electrodes ofthe electrode cartridge may be disposed to generate chlorine forsanitizing the spa water.

According to another aspect, an electrode cartridge adapted to beinstalled into a housing by a user of a spa is provided comprising ahandle component grippable by the user to insert the electrode cartridgeinto the housing and to pull the electrode cartridge out of the housingfor replacement. In one embodiment, first and second electrodes aremounted beneath the handle for generating chlorine from spa water, andfirst and second electrical contacts are positioned to come intoelectrical contact with first and second electrical contacts located onan interior surface of the housing when the electrode cartridge is in aninstalled position in the housing.

According to another aspect, an electrode cartridge is providedcomprising first and second electrodes each of which include a verticalportion which forms into a horizontal base portion from which extends anoutwardly curved spring arm electrical contact. According to anotheraspect, the horizontal base portions of each of the first and secondelectrodes respectively fit into a respective mating opening in anelectrode cup. In one embodiment, each horizontal base portion may beheld in place by a bottom surface of a handle component of the electrodecartridge.

According to another aspect, a chlorine generator apparatus is providedwherein a housing comprises first and second internal electrical contactterminals formed on an inner surface thereof and wherein spring armportions of the first and second electrodes of an electrode cartridgeform electrical contact surfaces which are positioned to make electricalcontact with the first and second internal electrical contact terminalswhen the electrode cartridge is fully inserted into the housing.

According to another aspect, a chlorine generator apparatus is providedcomprising a groove formed in an inner wall of an electrode cartridgehousing and first and second locking bars having first and secondprojections on respective outer ends thereof and mounted to slidelaterally in an electrode cartridge such that the first and secondprojections can come into engagement with the groove in the housinginner wall in order to lock the electrode cartridge in position. Aspring loaded plunger mounted in the electrode cartridge is shaped andpositioned to cause the first and second locking bars to move laterallysuch that the first and second projections come into engagement with thegroove.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side view of a chlorine generator system accordingto an illustrative embodiment installed in a spa;

FIG. 2 is a perspective view of the chlorine generator employed in thesystem of FIG. 1;

FIG. 3 is a top view of the chlorine generator of FIG. 2;

FIG. 4 is an exploded perspective view of the electrode housing of thechlorine generator of FIG. 2;

FIG. 5 is a sectional perspective view of the chlorine generator of FIG.2 taken at V-V of FIG. 3;

FIG. 6 is a perspective view of an electrode cartridge component of thechlorine generator of FIG. 2;

FIG. 7 is a top view of the electrode cartridge component of FIG. 6;

FIG. 8 is an exploded perspective view of the electrode cartridgecomponent of FIG. 6;

FIG. 9 is a perspective sectional view of the electrode cartridgecomponent of FIG. 6 taken at IX-IX of FIG. 7;

FIG. 10 is a sectional view illustrative of an electrode cartridgelocking mechanism according to an illustrative embodiment in a firstposition;

FIG. 11 is a sectional view of the illustrative electrode cartridgelocking mechanism of FIG. 10 in a second position;

FIG. 12 is a sectional view of the chlorine generator of FIG. 2; and

FIG. 13 is a perspective view of the open upper end of the electrodehousing of FIG. 4.

DETAILED DESCRIPTION

A chlorine generator system according to an illustrative embodiment isshown in FIG. 1. The illustrative system includes an electricalcontroller 13 and a chlorine generator 11 mounted in a bar top 12 of aspa 14. As may be appreciated, the bar top is an example of a useraccessible surface of the spa where a user may be, for example, a useror owner of the spa 14. In one embodiment, the spa 14 may be a portablespa.

The chlorine generator 11 comprises an electrode cartridge housing 15and an electrode cartridge 17. In the illustrative embodiment, theelectrode cartridge 17 carries a pair of electrodes 53, 55, and isremovably installed in the electrode cartridge housing 15. In oneembodiment, the housing 15 is keyed to the electrode cartridge 17 toinsure that the cartridge 17 may only be installed in the housing 15 ina proper manner. In an illustrative embodiment, water from the spacirculation path is routed up to the housing 15, through the electrodes53, 55 and back out of the housing 15 to the spa 14.

In an illustrative embodiment, the electrical controller 13 controlsgeneration of chlorine by the electrode cartridge 17. In one embodiment,the electrical controller 13 is relatively small in size, poweredthrough the spa control system 16, and fully integrated into the spa 14.In one embodiment, the electrical controller 13 utilizes an RS485communication protocol to transmit data and communicate with the spacontrol system 16. In one embodiment, the spa control system 16 may beaccessed through and driven by a spa control panel 18. In anotherembodiment, a closed loop control system may be employed which includesa sensor which measures, for example, one or more of: chlorine, bromine,ozone, ORP, pH, conductivity, alkalinity, cyanuric acid, water hardnessand/or temperature. The sensor then feeds parameters to an electroniccontroller which then automatically causes generation of the appropriateamount of chlorine via the chlorine generator 11.

In the illustrative embodiment, operation of the chlorine generator 11is controlled by user settings for chlorine output made at the spacontrol panel 18. In an illustrative embodiment, the electricalcontroller 13 drives the electrodes of the chlorine generator 11 in aconstant current mode to enable an optimal or desired chlorinegeneration rate. This mode of operation also allows the system to bedriven at different specific current levels to control the generationrate of chlorine per hour depending on the user settings.

In one embodiment, the spa water is salted, for example, by addingsodium chloride to achieve a concentration of, for example, 2000 ppm.Such an embodiment may be characterized as a salt water chlorinatorsystem.

As shown in FIGS. 2-5, in an illustrative embodiment, the electrodecartridge housing 15 comprises a wall fitting 19, which has circulargroove 20, which receives an edge, e.g. 101 (FIG. 1), of the spa bar top12. The wall fitting 19 mounts to the bar top 12 via a centering ring 23and a nut 25. A cap 27 is screwed to the wall fitting 19 on the userside of the system to provide access to the electrode cartridge 17. Aninternal web portion 24 of the cap 27 also positions and holds theelectrode cartridge 17 in place during operation.

In an illustrative embodiment, an upper portion 29 of a lower housingsection 22 glues into or otherwise attaches to the wall fitting 19 toform a watertight attachment. An O-ring 30 mounts in a receptacle in thewall fitting 19 and provides a watertight seal between the wall fitting19 and the cap 27. In illustrative embodiments, the wall fitting 19, cap27, and lower housing section 22, may all be a suitable molded plasticmaterial, such as, for example PVC or ABS plastic.

In the illustrative embodiment, the electrical connection of theelectrode cartridge 17 to the controller 13 via electrical leads 103,105 (FIG. 1) is completed through a pair of titanium electrical contacts31, 33, which are molded into the housing 15 in watertight fashion. Thecontacts 31, 33 have flat vertical terminals 34, 36 adjacent an insidesurface of the housing 15, as well as quick disconnect terminals 35, 37on the outside of the housing 15. The electrical contacts 31, 33 thusenable dry electrical connections to the chlorine generator 11 and easeof service of the system.

Below the electrical contacts 31, 33 is a drain port 41. This port 41allows for removal of any water that may have entered the dry portion ofthe housing 15 during removal and replacement of the electrode cartridge17. A water inlet port 43 on the bottom 45 of the housing 15 allows spawater to enter the housing 15 and flow through the wet electrode chamber47. At the top of the wet electrode chamber 47 is an outlet port 49through which the chlorinated spa water flows into the spa 14. Thevertical water flow through the housing 15 ensures efficient flushing ofthe housing 15 and removal of all liquids and gases generated in thehousing 15 during operation of the chlorinator 11.

As shown in FIGS. 6-9, in an illustrative embodiment, the electrodecartridge 17 comprises a tee handle 51 and pair of mixed metal oxidetitanium electrodes 53, 55. In illustrative embodiments, the electrodes53, 55 may comprise, for example, titanium or niobium base metal with asuitable oxide coating, such as, for example, ruthenium oxide, iridiumoxide, or platinum oxide. In other embodiments, the electrodes could beboron/nitrogen doped diamond.

In the illustrative embodiment, the electrodes 53, 55 are each formed asa single piece and each includes a respective rectangular verticalportion 52, 54, which forms into a respective horizontal base portion56, 58, from which extends respective outwardly curved spring armelectrical contact 57, 59. The electrodes 53, 55 could of course beformed of multiple parts in other embodiments, for example, withseparate wet electrode and spring contact components.

The horizontal base portions 56, 58 of each of the electrodes 53, 55each fit into a respective mating opening 67, 69 in an electrode cup 65and are held in place by a bottom surface 71 of the tee handle 51. AnO-ring 63 provides a watertight seal between the housing 15 and theelectrode cup 65.

First and second slots, e.g. 99, are defined in the electrode cup 65 oneither side of horizontal projections 110, 111, through which arespective one of the electrodes 53, 54 are inserted. Potting materialis applied to seal openings around the electrodes 53, 54. A cap 181covers the opening in the electrode cup 65 and prevents potting materialfrom leaking up through the opening. In an illustrative embodiment, thetee handle 51 and electrode cup 65 may be molded plastic componentsformed, for example, of PVC or ABS plastic.

In an illustrative embodiment, the design and shape of the electrodes53, 55 provide a single piece component extending from the wettedelectrode blade portions 52, 54 to the dry spring arm electricalcontacts 57, 59. The wetted blade portions 52, 54 of the electrodes 53,55 are equally spaced apart down the length of the cartridge 17, and aspacer 61 is mounted at the end of the cartridge 17 to ensure that theelectrodes 53, 55 are held in proper position. The dry spring armportions 57, 59 of the electrodes 53, 55 form electrical contactsurfaces which are spring-biased into electrical contact with the flatvertical electrical contact terminals 34, 36, located on the interior ofthe electrode housing 15.

As noted above, in one embodiment, the geometry of the electrodecartridge 17 permits installation of the electrode cartridge 17 into thehousing 15 in only one direction and orientation, insuring properelectrical contact. In particular, in the illustrative embodiment, theouter vertical edges of the rectangular plastic guards, 60, 62 aroundeach of the electrode contact arms 57, 59 extend outwardly and areshaped to mate with respective channels 74 defined by vertical guides70, 72 formed on the inner wall of the electrode housing 19, as shown inFIG. 13. The electrode cartridge 17 is thereby keyed to the housing 19,permitting the cartridge 17 to be inserted in only one orientation.

In one illustrative embodiment, a locking mechanism is used to securethe cartridge 17 in place within the housing 15 independent of the cap27. In particular, as shown in FIGS. 8 and 9, a spring loaded plunger isslidably mounted in an internal opening in the tee handle 51 andcomprises a bottom shaft 75, a spring 77 and a plunger cap 79.Respective locking bars 81, 83 with ball-shaped end surfaces 85, 87 arepositioned to move laterally in respective channels 86, 88 (FIG. 10)formed in the lower end of the tee handle 51. Oblong slots 88, 90, areformed in each of the locking bars 81, 83 to permit the locking bars 81,83 to move laterally left and right with respect to the attachmentscrews 50, which attach the tee handle 51 to the electrode cup 65.

As a result of this construction, the cartridge 17 cannot be installedin the housing 15 without first pushing the plunger down by depressingthe plunger cap 79 to retract the balls 85, 87 to a position within therespective channels 86, 88 in the lower end of the handle 51, asillustrated in FIG. 10. Once the balls 85, 87, are positioned adjacentthe channel 90 in the housing 15, as shown in FIG. 10, the plunger canbe pulled upward to the position shown in FIG. 11 so as to force lateralmovement of the locking bars 81, 83, thereby causing the balls 85, 87 toenter the locking position shown in FIG. 11. If the cartridge 17 is notfully inserted into its proper position in the housing 15, thedimensioning of the cap 27 will cause the cap 27 to push the cartridge17 into the locked position of FIG. 11 when the cap 27 is installed. Ifthe cap 27 is thereafter removed, the cartridge 17 remains in its properplace.

To remove the cartridge 17, the tee handle 51 may be grasped with twofingers and the plunger cap 79 depressed with the thumb, therebyreleasing the locking balls 85, 87 and allowing them to slide back. Thecartridge 17 may then be lifted out of the housing 19.

Illustrative embodiments provide numerous advantages and improvementsand in particular a low cost, disposable, consumer replaceable electrodecartridge, which is removable from the top side of a spa. Illustrativeembodiments enable dry removal of the electrode cartridge, avoiding therisk of electrical shock. Spa-side control and operation of the systemis also provided.

Significantly lower water maintenance requirements are also achieved byillustrative embodiments because the electrode cartridge is designed tolast a short life and to be disposable. Hence, the necessity to controlspa water parameters in order to maintain chlorine generator electrodesin operating condition is minimized or eliminated. For example,softening the spa water can help to minimize the need to clean theelectrodes. The illustrative embodiments eliminate the need to clean theelectrodes and hence the need to control spa water parameters in orderto maintain the electrodes. Thus, when the electrode cartridge is spent(no longer operating in spec) the system instructs the owner to changeit out.

From the foregoing, those skilled in the art will appreciate thatvarious adaptations and modifications of the just described illustrativeembodiments can be configured without departing from the scope andspirit of the invention. Therefore, it is to be understood that, withinthe scope of the appended claims, the invention may be practiced otherthan as specifically described herein.

What is claimed is:
 1. A method of constructing an electrode cartridgefor a chlorinator apparatus comprising: forming a handle componentgrippable by a user; mounting first and second electrodes beneath thehandle; shaping the electrode cartridge to be slidably insertable intoand slidably removable from a mating housing; and positioning first andsecond electrical contacts on the electrode cartridge so as to come intocontact with first and second electrical contacts located on the matinghousing when the electrode cartridge is inserted into an installedposition in the mating housing.
 2. The method of claim 1 furthercomprising: installing the electrode cartridge in the mating housing;signaling a user when the electrode cartridge is spent to facilitateremoval and replacement of the cartridge; and removing the spentelectrode cartridge from the mating housing in response to saidsignaling.
 3. The method of claim 2 further comprising replacing thespent electrode cartridge by slidably inserting a second electrodecartridge into the mating housing, the second electrode cartridge havingbeen constructed using the method of claim
 1. 4. The method of claim 1further comprising installing the electrode cartridge in the matinghousing; and replacing the electrode cartridge when it is spent byslidably inserting a second electrode cartridge into the mating housing,the second electrode cartridge having been constructed using the methodof claim
 1. 5. The method of claim 1 further comprising configuring theelectrode cartridge such that no electrical wires enter or are attachedto the electrode cartridge when the electrode cartridge is in aninstalled position in the mating housing.
 6. The method of claim 1further comprising configuring the electrode cartridge such that thefirst and second electrical contacts of the electrode cartridgeconstitute the only respective entry and exit points for electricalcurrent into and out of the electrode cartridge.
 7. The method of claim1 further comprising configuring the electrode cartridge such thatelectrical contact with the mating housing is broken simply by pullingthe electrode cartridge out of the housing.
 8. A method of constructingan electrode cartridge comprising: forming a single piece firstelectrode so as to include a vertical portion configured to generatechlorine and such that the vertical portion forms into a horizontal baseportion from which extends an outwardly curved spring arm electricalcontact; and forming a single piece second electrode so as to include avertical portion configured to generate chlorine and such that thevertical portion forms into a horizontal base portion from which extendsan outwardly curved spring arm electrical contact.
 9. The method ofclaim 8 further comprising forming each outwardly curved spring armelectrical contact such that it extends upwardly from its respectivehorizontal base portion.
 10. A method of constructing an electrodecartridge for a chlorinator apparatus comprising: forming a handlegrippable by a user; mounting first and second electrodes beneath thehandle; shaping the electrode cartridge to be slidably insertable intoand slidably removable from a mating housing; positioning a firstelectrical contact on an exterior side surface of the electrodecartridge in a position selected such that the first electrical contactwill come into electrical contact with a first electrical contactlocated on a side surface of the mating housing when the electrodecartridge is inserted into an installed position in the mating housing;and positioning a second electrical contact on an exterior side surfaceof the electrode cartridge in a position selected such that the secondelectrical contact will come into electrical contact with a secondelectrical contact located on a side surface of the mating housing whenthe electrode cartridge is inserted into the installed position in themating housing.
 11. The method of claim 10 further comprisingconfiguring the first and second electrical contacts of the electrodecartridge to each function as part of an electrical switch.
 12. Themethod of claim 10 further comprising imparting a spring bias to thefirst and second electrical contacts of the electrode cartridge.
 13. Themethod of claim 10 further comprising: installing the electrodecartridge in the mating housing; signaling the user when the electrodecartridge is spent to facilitate removal and replacement of thecartridge; and removing the spent electrode cartridge from the matinghousing in response to said signaling.
 14. The method of claim 13further comprising replacing the spent electrode cartridge by slidablyinserting a second electrode cartridge into the mating housing, thesecond electrode cartridge having been constructed using the method ofclaim
 10. 15. The method of claim 10 further comprising installing theelectrode cartridge in the mating housing; and replacing the electrodecartridge when it is spent by slidably inserting a second electrodecartridge into the mating housing, the second electrode cartridge havingbeen constructed using the method of claim
 10. 16. The method of claim10 further comprising configuring the electrode cartridge such that noelectrical wires enter or are attached to the electrode cartridge whenthe electrode cartridge is in an installed position in the matinghousing.
 17. The method of claim 10 further comprising configuring theelectrode cartridge such that the first and second electrical contactsof the electrode cartridge constitute the only respective entry and exitpoints for electrical current into and out of the electrode cartridge.18. The method of claim 10 further comprising configuring the electrodecartridge such that electrical contact with the mating housing is brokensimply by pulling the electrode cartridge out of the housing.